Process and apparatus for making channeled absorbent articles

ABSTRACT

A method for making an absorbent article comprising an absorbent core comprising one or more channels, the method comprising the steps of: i. providing a first endless moving surface comprising a plurality of molds, each mold comprising a non-porous insert therein, typically said insert having the inverse shape of said channel(s), wherein the molds are in fluid communication with an under-pressure source except for said insert; ii. feeding a first nonwoven web to said first endless moving surface and over one or more said molds; iii. depositing an absorbent material, comprising cellulose fibers and/or superabsorbent polymer particles, over at least a portion of said nonwoven web; iv. removing said absorbent material from areas of the nonwoven web corresponding to said insert; v. applying a second nonwoven web directly or indirectly over the absorbent material, or folding said first nonwoven web, such to sandwich said absorbent material between upper and lower layers of said nonwoven web(s); vi. joining said upper and lower layers together at least in the areas of the nonwoven web(s) corresponding to the insert to form an absorbent core having one or more channels substantially free of absorbent material; vii. optionally joining an acquisition distribution layer to said absorbent core, typically a skin facing surface of said upper layer; viii. optionally laminating said absorbent core and acquisition distribution layer between a liquid pervious topsheet and a liquid impervious backsheet; wherein step vi. comprises the step of selectively applying a first pressure onto the absorbent core, preferably only, in a central portion thereof and a second pressure, preferably only, along peripheral longitudinal side edges thereof miming opposite and parallel to each other and being outboard of said central portion, said central portion corresponding at least to a region of the core comprising said channel(s), and wherein said first and second pressures are successively applied along a machine direction (MD).

TECHNICAL FIELD

The disclosure pertains to the technical field of absorbent hygieneproducts and methods of making thereof. In particular, the presentdisclosure relates to apparatus and methods of making absorbent systemscomprising an absorbent core and further distribution layers (such asacquisition distribution layers and/or core wrap layers typically havingadditional functional characteristics of said acquisition distributionlayers) that can be used within an article for absorbing body fluids andexudates, such as urine and fecal material, or blood, menses, andvaginal fluids. More particularly, the present disclosure relates toabsorbent garments (or articles), such as disposable diapers or diaperpants, disposable incontinence diapers or pants, and which areconfigured to collect and contain fecal material and avoid leakage, orsanitary napkins or panty liners, which are configured to collect andcontain blood, menses, urine, vaginal fluids and avoid leakage.

BACKGROUND

The disclosure relates to apparatus and process of making an absorbentcore for an absorbent article, in particular for hygiene articles, toabsorbent articles comprising said absorbent core and to processes forproviding said absorbent core. In particular to cores having one or morechannels therethrough.

Absorbent cores have been subject to considerable improvement andinnovation over time to address needs such as improved fluid absorptionand distribution, as well as comfort, and a need for continuedimprovement exists. Such needs are ever present in today's demandingconsumer environment. The following paragraphs elucidate on some of therelevant disclosures pertaining to this subject.

EP 1077052 A1 and EP 1078617 A2 disclose a sanitary napkin allowingcontrolled deformation in response to lateral compression when in use.The sanitary napkin has preferential bending zones extending along alongitudinal axis formed by a process of perforating, slitting, cuttingor embossing.

EP 1959903 B1 discloses an incontinence pad comprising a pair of foldinglines dividing the absorbent core material into a central portion and apair of longitudinal side portions to adapt better to the body of theuser. The folding lines are formed by compression of the absorbentmaterial.

EP 2211808 B1 discloses an absorbent core comprising an upper absorbentcore and a lower absorbent core. The upper absorbent core comprises foldindications enabling the absorbent core to adopt a predeterminedthree-dimensional shape when subjected to pressure in the widthdirection. The fold indications are cuts or compression lines which door do not extend completely through the upper core.

EP 1349524 B1 discloses a pantiliner comprising at least one fold linedefining a central area and two side areas which allows adjusting thesize of the pantiliner by folding the pantiliner along the fold line.The fold lines are lines of embossing.

EP 1267775 B1 discloses a sanitary pad that conforms to the bodyconfinements. The sanitary pad comprises a forward wide portion and arear narrow portion and at least two fold lines preformed on the upperor lower surface of the narrow portion. The fold lines may be selectedfrom mechanically pressed lines, chemically joined constituents formingthe lines, heat generated lines, laser generated lines, adhesivegenerated lines and/or mechanical vibration generated lines.

EP1088536 A2 discloses a hygiene napkin provided with corrugationsmaking it possible to adapt the hygienic napkin to the user's panties.

U.S. Pat. No. 5,756,039 A discloses an absorbent core comprisingdistinct segments which can be independently displaced by a liftingmember. The lifting member ensures that the top sheet conforms to thewearer's body.

US 2006/0184150 A1 discloses an absorbent core with varying flexibilitythat act as shaping element for improved body fit. The absorbent corecan have lines of reduced bending resistance which are formed by removalof material, e.g. in the form of apertures or slots.

U.S. Pat. No. 6,503,233 B1 discloses an absorbent article comprising acombination of downwardly-deflecting crease lines and anupward-deflecting shaping line to achieve a geometry for improved bodyfit. The crease lines are formed by embossing of the absorbent material.The shaping line is formed by perforation or notching.

US 2015/0088084 A1, discloses a method of making an absorbent structurehaving a three-dimensional topography including placing at least aportion of the absorbent structure between opposed mold surfaces. Atleast one of the mold surfaces has a three-dimensional topography. Thethree-dimensional topography of the mold surface is imparted onto theabsorbent structure so that the absorbent structure has athree-dimensional topography corresponding to the three-dimensionaltopography of the mold surface.

EP3342386A1, discloses an absorbent core comprising substantiallycontinuous zones of one or more high fluid distribution structures anddiscontinuous zones of fluid absorption structures surrounding the oneor more high fluid distribution structures, wherein the one or more highfluid distribution structures are arranged to distribute fluid acrossthe absorbent core at a speed that is faster than the speed of fluiddistribution across the absorbent core by said discontinuous fluidabsorption structures, and wherein said continuous zones extend along apath that is substantially parallel to at least a portion of theperimeter of the core, said portion of the perimeter of the corecomprising at least a portion of the sides of the core and one of theends of the core.

Apparatuses and processes of making such cores are described inEP3342386A1 and comprise the use of a 3D insert having the inverse shapeof the desired channels in combination with a vacuum source. It isnevertheless desirable to improve adhesion between top and bottom layersof the core wrap forming the absorbent material free channels.

EP2905001A1, discloses an apparatus and method for making an absorbentstructure for an absorbent article, comprising a supporting sheet andthereon an absorbent layer, the absorbent layer comprising an absorbentmaterial. According to the disclosure a first moving endless surface isprovided which has one or more substantially longitudinally extendingfirst mating strips, and at least one further auxiliary moving endlesswith second mating strips on its surface is provided which act againstthe first mating strips. Pressure is applied between the first andsecond mating strips and to the first and second supporting sheets atleast within a part of the area of the channels, so as to adheretogether the first and second supporting sheets. Such mating striparrangement requires locating the further auxiliary moving endlesssurface to act directly onto the first moving endless surface in orderto avoid the need for a registered process.

A need nevertheless exists for improving adhesion of core wrap sheets inabsorbent cores comprising channels that allow for improved processflexibility and that limits wear and tear of respective apparatuscomponents especially at high production speeds for extended continuousperiods of time.

SUMMARY

In a first aspect, the disclosure relates to a method for making anabsorbent article comprising an absorbent core comprising one or morechannels, the method comprising the steps of: i. providing a firstendless moving surface comprising a plurality of molds, each moldcomprising a non-porous insert therein, typically said insert having theinverse shape of said channel(s), wherein the molds are in fluidcommunication with an under-pressure source except for said insert; ii.feeding a first nonwoven web to said first endless moving surface andover one or more said molds; iii. depositing an absorbent material,comprising cellulose fibers and/or superabsorbent polymer particles,over at least a portion of said nonwoven web; iv. removing saidabsorbent material from areas of the nonwoven web corresponding to saidinsert; v. applying a second nonwoven web directly or indirectly overthe absorbent material, or folding said first nonwoven web, such tosandwich said absorbent material between upper and lower layers of saidnonwoven web(s); vi. joining said upper and lower layers together atleast in the areas of the nonwoven web(s) corresponding to the insert toform an absorbent core having one or more channels substantially free ofabsorbent material; vii. optionally joining an acquisition distributionlayer to said absorbent core, typically a skin facing surface of saidupper layer; viii. optionally laminating said absorbent core andacquisition distribution layer between a liquid pervious topsheet and aliquid impervious backsheet; wherein step vi. comprises the step ofselectively applying a first pressure onto the absorbent core,preferably only, in a central portion thereof and a second pressure,preferably only, along peripheral longitudinal side edges thereofrunning opposite and parallel to each other and being outboard of saidcentral portion, said central portion corresponding at least to a regionof the core comprising said channel(s), and wherein said first andsecond pressures are successively applied along a machine direction(MD).

In a second aspect, the disclosure relates to a method for making anabsorbent article comprising an absorbent core comprising one or morechannels, the method comprising the steps of: i. providing a firstendless moving surface comprising a plurality of molds, each moldcomprising a non-porous insert therein, typically said insert having theinverse shape of said channel(s), wherein the molds are in fluidcommunication with an under-pressure source except for said insert; ii.feeding a first nonwoven web to said first endless moving surface andover one or more said molds; iii. depositing an absorbent material,comprising cellulose fibers and/or superabsorbent polymer particles,over at least a portion of said nonwoven web; iv. removing saidabsorbent material from areas of the nonwoven web corresponding to saidinsert; v. applying a second nonwoven web directly or indirectly overthe absorbent material, or folding said first nonwoven web, such tosandwich said absorbent material between upper and lower layers of saidnonwoven web(s); vi. joining said upper and lower layers together atleast in the areas of the nonwoven web(s) corresponding to the insert toform an absorbent core having one or more channels substantially free ofabsorbent material; vii. optionally joining an acquisition distributionlayer to said absorbent core, typically a skin facing surface of saidupper layer; viii. optionally laminating said absorbent core andacquisition distribution layer between a liquid pervious topsheet and aliquid impervious backsheet; wherein step vi. comprises the step ofselectively applying a first pressure onto the absorbent core,preferably only, in a central portion thereof and a further pressureonto the absorbent core, preferably only, in the central portionthereof, wherein said further pressure is applied upstream of said firstpressure and arranged to provide a pre-compression force onto theabsorbent core in an area of said core corresponding to said channels.

In a third aspect, the disclosure relates to an apparatus for making anabsorbent article comprising an absorbent core comprising one or morechannels, said apparatus comprising: a first endless moving surface inthe form of a rotating drum, said drum comprising a plurality of moldsin the form of pockets successively positioned along a circumference ofsaid drum, wherein each mold comprises a non-porous insert therein, saidinsert preferably having the inverse shape of said channel(s), whereinthe molds are in fluid communication with an under-pressure sourceexcept for said insert such to form one or more non-suction zonescorresponding to said non-porous insert and a suction zone surroundingsaid non-porous insert; a first feeding unit for feeding a firstnonwoven web to said first endless moving surface and over one or moresaid molds; a first adhesive application unit for applying an adhesivepattern over a skin-facing surface of said first nonwoven web; anabsorbent material deposition unit for depositing an absorbent material,typically comprising cellulose fibers and/or superabsorbent polymerparticles, over at least a portion of said first nonwoven web; a secondfeeding unit for feeding a second nonwoven web directly or indirectlyover the absorbent material such to sandwich said absorbent materialbetween upper and lower layers of said nonwoven webs to form anabsorbent core; or a folding unit for folding said first nonwoven websuch to sandwich said absorbent material between upper and lower layersof said nonwoven web to form an absorbent core; optionally a secondadhesive application unit for applying an adhesive pattern over agarment-facing surface of said second nonwoven web positioned upstream ajoining position of said second nonwoven web to said first nonwoven web;optionally a removing unit for removing said absorbent material fromareas of the nonwoven web corresponding to said insert such that atleast one portion of the nonwoven web located above the suction zone iscovered with absorbent material and substantially no absorbent materialis present on portions corresponding to the non-suction zone; a firstauxiliary endless moving surface for applying a first pressure to theupper and lower layers of said nonwoven web(s); wherein the apparatusfurther comprises a second and third auxiliary endless moving surfacesfor applying a second pressure to the upper and lower layers of saidnonwoven web(s), wherein said first endless moving surface, said firstauxiliary endless moving surface, said second auxiliary endless movingsurface and said third auxiliary endless moving surface each have anaxis of rotation being substantially parallel to each other, and whereinthe first endless moving surface and the auxiliary endless movingsurfaces act upon each other by applying pressure to the upper and lowerlayers of said nonwoven web(s), and wherein said first auxiliary endlessmoving surface is arranged to selectively apply said first pressure ontothe absorbent core, preferably only, in a central portion thereof andsaid second and third auxiliary endless moving surfaces are arranged toselectively apply said second pressure, preferably only, alongperipheral longitudinal side edges of said absorbent core runningopposite and parallel to each other and being outboard of said centralportion, said central portion corresponding at least to a region of thecore comprising said channel(s).

In a further aspect, the disclosure relates to the use of an apparatus,according to the above and disclosed embodiments herein, in making anabsorbent article comprising an absorbent core comprising one or morechannels, wherein top and bottom layers of the nonwoven web(s) arejoined together in an area corresponding to the channel(s) and,preferably sequentially thereafter, in areas corresponding to theperipheral longitudinal side edges of said absorbent core runningopposite and parallel to each other and being outboard of the centralportion of the absorbent core comprising the channel(s), for increasingproduction speed and/or avoiding process registration

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a perspective view of a portion of an apparatus accordingto an embodiment herein.

FIG. 2 shows a side view of the apparatus of FIG. 1.

FIG. 3 shows a perspective view of a portion of an apparatus accordingto an embodiment herein.

FIG. 4 shows a side view of the apparatus of FIG. 3.

FIG. 5 is a side view illustration of auxiliary endless movingsurface(s) according to an embodiment herein.

FIG. 6 is a schematic drawing illustrating a process according to anembodiment herein.

FIG. 7 is a schematic cross-section of pockets comprising an insertaccording to an embodiment herein.

DETAILED DESCRIPTION

Unless otherwise defined, all terms used in disclosing characteristicsof the disclosure, including technical and scientific terms, have themeaning as commonly understood by one of ordinary skill in the art towhich this disclosure belongs. By means of further guidance, termdefinitions are included to better appreciate the teaching of thepresent disclosure.

As used herein, the following terms have the following meanings:

“A”, “an”, and “the” as used herein refers to both singular and pluralreferents unless the context clearly dictates otherwise. By way ofexample, “a compartment” refers to one or more than one compartment.

“About” as used herein referring to a measurable value such as aparameter, an amount, a temporal duration, and the like, is meant toencompass variations of +/−20% or less, preferably +/−10% or less, morepreferably +/−5% or less, even more preferably +/−1% or less, and stillmore preferably +/−0.1% or less of and from the specified value, in sofar such variations are appropriate to perform in the discloseddisclosure. However, it is to be understood that the value to which themodifier “about” refers is itself also specifically disclosed.

“Comprise”, “comprising”, and “comprises” and “comprised of” as usedherein are synonymous with “include”, “including”, “includes” or“contain”, “containing”, “contains” and are inclusive or open-endedterms that specifies the presence of what follows e.g. component and donot exclude or preclude the presence of additional, non-recitedcomponents, features, element, members, steps, known in the art ordisclosed therein.

The expression “% by weight” (weight percent), here and throughout thedescription unless otherwise defined, refers to the relative weight ofthe respective component based on the overall weight of the formulation.

The recitation of numerical ranges by endpoints includes all numbers andfractions subsumed within that range, as well as the recited endpointsunless otherwise stated.

“Absorbent article” refers to devices that absorb and contain liquid,and more specifically, refers to devices that are placed against or inproximity to the body of the wearer to absorb and contain the variousexudates discharged from the body. Absorbent articles include but arenot limited to diapers, adult incontinence briefs, training pants,diaper holders and liners, sanitary napkins and the like, as well assurgical bandages and sponges. Absorbent articles preferably comprise alongitudinal axis and a transversal axis perpendicular to saidlongitudinal axis. The longitudinal axis is hereby conventionally chosenin the front-to-back direction of the article when referring to thearticle being worn, and the transversal axis is conventionally chosen inthe left-to-right direction of the article when referring to the articlebeing worn. Disposable absorbent articles can include a liquid pervioustop sheet, a back sheet joined to the top sheet, and an absorbent corepositioned and held between the top sheet and the back sheet. The topsheet is operatively permeable to the liquids that are intended to beheld or stored by the absorbent article, and the back sheet may or maynot be substantially impervious or otherwise operatively impermeable tothe intended liquids. The absorbent article may also include othercomponents, such as liquid wicking layers, liquid intake layers, liquiddistribution layers, transfer layers, barrier layers, wrapping layersand the like, as well as combinations thereof. Disposable absorbentarticles and the components thereof can operate to provide a body-facingsurface and a garment-facing surface.

An absorbent article, such as a diaper, comprises a front waistbandregion, a back waistband region, an intermediate crotch region whichinterconnects the front and rear waistband regions. When used herein,reference to a “front” portion refers to that part of the absorbentarticle which is generally located on the front of a subject, such as aninfant or adult, when in use. Reference to the “rear” portion refers tothe portion of the absorbent article generally located at the rear ofthe subject, such as an infant or adult, when in use, and reference tothe “crotch” portion refers to that portion which is generally locatedbetween the legs of subject, such as an infant or adult, when in use.The crotch region is an area where repeated fluid surge typicallyoccurs, within the absorbent article assembly.

“Mechanical bond” is an attachment between two or more elements,components, regions, or webs and may comprise heat bonds, pressurebonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitablenon-adhesive attachment means or combinations of these attachment meansas are known in the art.

“Acquisition and distribution layer”, “ADL” or “surge managementportion” refers to a sub-layer which preferably is a nonwoven wickinglayer under the top sheet of an absorbent product, which speeds up thetransport and improves distribution of fluids throughout the absorbentcore. The surge management portion is typically less hydrophilic thanthe retention portion, and has the ability to quickly collect andtemporarily hold liquid surges, and to transport the liquid from itsinitial entrance point to other parts of the absorbent structure,particularly the retention portion. This configuration can help preventthe liquid from pooling and collecting on the portion of the absorbentgarment positioned against the wearer's skin, thereby reducing thefeeling of wetness by the wearer. Preferably, the surge managementportion is positioned between the top sheet and the retention portion.

The term “adhesive” as used herein is intended to refer to any suitablehot melt, water or solvent borne adhesive that can be applied to asurface of a film layer in the required pattern or network of adhesiveareas to form the film-nonwoven laminate of the present disclosure.Accordingly, suitable adhesives include conventional hot melt adhesives,pressure-sensitive adhesives and reactive adhesives (i.e.,polyurethane).

As used herein, the “skin facing”, “body-facing” or “bodyside” surfacemeans that surface of the article or component which is intended to bedisposed toward or placed adjacent to the body of the wearer duringordinary use, while the “outward”, “outward-facing” or “garment-side”surface is on the opposite side, and is intended to be disposed to faceaway from the wearer's body during ordinary use. Such outward surfacemay be arranged to face toward or placed adjacent to the wearer'sundergarments when the absorbent article is worn.

“Bonded” refers to the joining, adhering, connecting, attaching, or thelike, of at least two elements. Two elements will be considered to bebonded together when they are bonded directly to one another orindirectly to one another, such as when each is directly bonded tointermediate elements.

The term “consisting essentially of” does not exclude the presence ofadditional materials which do not significantly affect the desiredcharacteristics of a given composition or product. Exemplary materialsof this sort would include, without limitation, pigments, antioxidants,stabilizers, surfactants, waxes, flow promoters, solvents, particulatesand materials added to enhance processability of the composition.

The term “disposable” is used herein to describe absorbent articles thatgenerally are not intended to be laundered or otherwise restored orreused as an absorbent article (i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner).

As used herein, the terms “elastic”, “elastomeric”, “elasticity” orderivations thereof are used to describe the ability of variousmaterials and objects comprised of such to reversibly undergodeformation under stress, e.g., become stretched or extended, in atleast one direction when a force is applied to the material and toresume substantially to their original dimensions upon relaxing, i.e.,when the force is released, without rupture or breakage. Preferably, itrefers to a material or composite which can be elongated in at least onedirection by at least 50% of its relaxed length, i.e., elongated to atleast 150% of its relaxed length, and which will recover upon release ofthe applied tension at least 40% of its elongation. Accordingly, uponrelease of the applied tension at 50% elongation, the material orcomposite contracts to a relaxed length of not more than 130% of itsoriginal length. Examples of suitable elastomer materials includepolyether-polyamide block copolymers, polyurethanes, synthetic linearA-B-A and A-B block copolymers, chlorinated rubber/EVA (ethylene-vinylacetate) blends, EPDM (ethylene-propylene diene monomer) rubbers, EPM(ethylene-propylene monomer) rubbers, blends of EPDM/EPM/EVA, and thelike.

As used herein, the term “garment” means any type of apparel which maybe worn. This includes diapers, training pants, incontinence products,surgical gowns, industrial workwear and coveralls, undergarments, pants,shirts, jackets and the like.

“Join”, “joining”, “joined”, or variations thereof, when used indescribing the relationship between two or more elements, means that theelements can be connected together in any suitable manner, such as byheat sealing, ultrasonic bonding, thermal bonding, by adhesives,stitching, or the like. Further, the elements can be joined directlytogether, or may have one or more elements interposed between them, allof which are connected together.

By “channels”, it is meant that the structure referred to (e.g. theabsorbent core) comprises recessed regions forming visible conduits orpassages typically extending along the longitudinal axis of the core andhaving a depth in a direction perpendicular to said longitudinal axis.By “visible” it is herein intended clearly visible by naked eye andtypically that the channels have a width generally greater than 1 mm,preferably from 5 mm to 50 mm, more preferably from 8 mm to 40 mm, morepreferably from 10 mm to 30 mm, even more preferably from greater than10 mm to less than 25 mm.

By “interconnected”, it is meant that the structure referred to (e.g.the channels) from a substantially continuous path such as from a firstend of a channel to a second end of the same channel.

By “substantially”, it is meant at least the majority of the structurereferred to. For example, with reference to interconnected channels,“substantially interconnected” means that the majority of the channel isinterconnected and generally wherein a direct and continuous path can betraced by starting from one end of the channel towards another end ofthe channel, said ends (also referred to herein as terminal positions)may be distal to each other in a width direction of the core andproximal to a portion of the perimeter of the core, preferably the sidesthereof.

By “directly over”, it is meant that the feature referred to is placedover the structure referred to such that the two are in direct contactwith each other at least throughout a substantial portion of saidstructure.

By “indirectly over”, it is meant that the feature referred to is placedover the structure referred to but in such a way that the two are not indirect contact with each other at least throughout a substantial portionof said structure. For example, a nonwoven web applied indirectly over athree-dimensional absorbent material comprises a further layer ofmaterial between said nonwoven web and said three-dimensional absorbentmaterial.

“Superabsorbent polymer particles” or “SAPs” refer to water-swellable,water-insoluble organic or inorganic materials capable, under the mostfavorable conditions, of absorbing at least about 10 times their weight,or at least about 15 times their weight, or at least about 25 timestheir weight in an aqueous solution containing 0.9 weight percent sodiumchloride. In absorbent articles, such as diapers, incontinent diapers,etc., the particle size is typically ranging between 100 to 800 μm,preferably between 300 to 600 μm, more preferably between 400 to 500 μm.

Embodiments of the articles and processes according to the disclosurewill now be described. It is understood that technical featuresdescribed in one or more embodiments maybe combined with one or moreother embodiments without departing from the intention of the disclosureand without generalization therefrom.

The Apparatus

As exemplified in FIG. 1-2, the apparatus (6) for making an absorbentarticle (as used herein absorbent articles typically being disposable)comprising an absorbent core comprising one or more channels, saidapparatus comprises: a first endless moving surface (1) in the form of arotating drum, said drum comprising a plurality of molds (2) in the formof pockets successively positioned along a circumference of said drum,wherein each mold (2) comprises a non-porous insert (3) therein, saidinsert (3) preferably having the inverse shape of said channel(s),wherein the molds (2) are in fluid communication with an under-pressuresource except for said insert (3) such to form one or more non-suctionzones corresponding to said non-porous insert (3) and a suction zonesurrounding said non-porous insert (3); a first feeding unit (7) forfeeding a first nonwoven web (4) to said first endless moving surface(1) and over one or more said molds (2); a first adhesive applicationunit (8) for applying an adhesive pattern over a skin-facing surface ofsaid first nonwoven web (4); an absorbent material deposition unit (9)for depositing an absorbent material, typically comprising cellulosefibers and/or superabsorbent polymer particles, over at least a portionof said first nonwoven web (4); a second feeding unit for feeding asecond nonwoven web (5) directly or indirectly over the absorbentmaterial such to sandwich said absorbent material between upper andlower layers of said nonwoven webs (4, 5) to form an absorbent core; ora folding unit for folding said first nonwoven web (4) such to sandwichsaid absorbent material between upper and lower layers of said nonwovenweb (4) to form an absorbent core; optionally a second adhesiveapplication unit (10) for applying an adhesive pattern over agarment-facing surface of said second nonwoven web (5) positionedupstream a joining position of said second nonwoven web (5) to saidfirst nonwoven web (4); optionally a removing unit (11) for removingsaid absorbent material from areas of the nonwoven web (4) correspondingto said insert (3) such that at least one portion of the nonwoven web(4) located above the suction zone is covered with absorbent materialand substantially no absorbent material is present on portionscorresponding to the non-suction zone; a first auxiliary endless movingsurface (12) for applying a first pressure to the upper and lower layersof said nonwoven web(s) (4, 5); wherein the apparatus (6) furthercomprises a second and third auxiliary endless moving surfaces forapplying a second pressure to the upper and lower layers of saidnonwoven web(s) (4, 5), wherein said first endless moving surface (1),said first auxiliary endless moving surface (12), said second auxiliaryendless moving surface (13) and said third auxiliary endless movingsurface (14) each have an axis of rotation being substantially parallelto each other, and wherein the first endless moving surface (1) and theauxiliary endless moving surfaces (12, 13, 14) act upon each other byapplying pressure to the upper and lower layers of said nonwoven web(s)(4, 5), and wherein said first auxiliary endless moving surface (12) isarranged to selectively apply said first pressure onto the absorbentcore, preferably only, in a central portion thereof and said second andthird auxiliary endless moving surfaces (13, 14) are arranged toselectively apply said second pressure, preferably only, alongperipheral longitudinal side edges of said absorbent core runningopposite and parallel to each other and being outboard of said centralportion, said central portion corresponding at least to a region of thecore comprising said channel(s). Advantageously, such selectiveapplication of pressure on the central part of the core and separatelyon the peripheral longitudinally extending edges (i.e. extendingparallel to the machine direction MD) of the core allows for appropriatejoining of the core wrap layers where its needed without the need ofprofiled pressure rollers and thus allowing to avoid the use of aregistered process and further to limit wear and tear of components andthus run at faster production speeds, all this with limited risk ofdamaging the core wrap layers by avoiding over-compression of theabsorbent material in regions of the core where the top and bottom corewrap layers are not to be joined.

In an embodiment, the removing unit (11) is in the form of a rotatingbrush that comprises a plurality of bristles. Alternatively, a staticbrush may be used or other means such as blowing of air that aresuitable to remove any excess absorbent material that may deposit on thenonwoven web corresponding to the channel or insert (3) (i.e. thenon-suction zone).

In an embodiment, the insert (3) has a thickness t along an axisperpendicular to both the axis of rotation of the first endless movingsurface (1) and the machine direction (MD), and the mold has a depth dalong an axis perpendicular to both the axis of rotation of the firstendless moving surface (1) and the machine direction (MD), wherein saidthickness t is greater than said depth d such that said insert protrudesoutwardly from an apex of said mold (2).

As illustrated in FIG. 7, pockets (2) herein have a perforated base(18), in fluid communication with the underpressure source generating avacuum force, longitudinal peripheral edges (19), and the non-porousinsert (3) that protrudes beyond the longitudinal peripheral edges toform a non-suction zone corresponding to the position where the top andbottom layers of the core wrap are joined to form absorbent materialfree channels. The insert (3) may be releasably joined to the base (18)of each pocket (2) via one or more screws, alternative joining means mayalso be used as long as the insert is releasably for quickinterchangeability and change over as may be needed.

In a preferred embodiment, the insert (3) is substantially U-shaped,this is useful for forming absorbent cores that comprise a singleinterconnected channel (substantially in the form of a U-shape)extending along both a longitudinal (corresponding to an axissubstantially parallel to the machine direction MD) and transverse axis(corresponding to an axis substantially parallel to the axis of rotationof the first endless moving surface, such as the drum core former, andperpendicular to the machine direction MD) of said core. Although, thisarrangement is preferred, it will be apparent to a person skilled in theart that other channel geometries may equally be attained by changingthe shape of the insert. For example interconnected shapes such assubstantially V-shaped, X-shaped, Ω-shaped, α-shaped, π-shaped,T-shaped, I-shaped, Y-shaped, etc. are equally contemplated herein. Theinterconnected channel may also be a single substantially I-shapedchannel extending along the centerline of the absorbent core and in thiscase the insert may be I-shaped and positioned to coincide with thecenterline of the pocket extending along the machine direction MD.Moreover, a plurality of channels (whether straight or curved) are alsocontemplated, for example by replacing the single interconnected insertper pocket with a plurality of inserts for each pocket wherein eachinsert has the shape of the desired channels that may be symmetricallydisposed on each side of a centerline of the pocket extending along themachine direction MD.

In an embodiment, the auxiliary moving surfaces herein are endless, suchas in the form of rollers as will be explained in more detail hereinbelow.

In an embodiment, the axis of rotation of the first auxiliary endlessmoving surface (12) is positioned at a first distance from the axis ofrotation of the first endless moving surface (1) and the second andthird auxiliary moving surfaces (13, 14) are positioned at a seconddistance from the axis of rotation of the first endless moving surface(1), and wherein said first distance is greater than said seconddistance. Advantageously, this allows to apply the correct pressure forjoining the longitudinal peripheral edges and central portion of thecore whilst limiting risk of damaging the core wrap layers or crushingthe superabsorbent polymer particles. Indeed, the peripheral edges ofthe core are free of absorbent material and typically extend along acircumferential distance that is closer to the axis of rotation of thefirst endless moving surface compared to the channel regions that sitover the insert as will be described in more detail below, and thus sucharrangement ensures not to apply unwanted high pressure on the centralportion of the core in areas other than the channel area to bond the topand bottom core wrap layers together in said region.

In an embodiment, the second and third auxiliary moving surfaces (13,14) are positioned downstream of the first auxiliary moving surface (12)along a machine direction (MD). It is desirable that the first auxiliaryendless moving surface (12) is closest possible to the marriage point ofthe top and bottom core wrap layers in order to ensure a good bond whenjoining the respective layers together in the channel regions. Thisensures limited contamination of the channel by absorbent material andhelps to maintain absorbent free channels through the joining step ofthe process.

Preferably, the second and third auxiliary moving surfaces (13,14) arespaced apart at a distance extending parallel to the axis of rotationthereof, preferably wherein the axis of rotation of said second andthird auxiliary surfaces (13, 14) substantially coincide, morepreferably wherein the second and third auxiliary moving surfaces (13,14) are rotatably connected by a common housing. Advantageously, thisarrangement allows to apply pressure in the peripheral longitudinalareas of the core only, and thus avoid pressing on other regions of thecore that comprise absorbent material, such as the central regionthereof.

Preferably, as illustrated in FIG. 3-4, the apparatus comprises a fourthauxiliary moving surface (15) arranged to provide a third pressure ontothe absorbent core, preferably only, in the central portion thereof,wherein said third pressure is applied upstream of said first pressure,preferably said third pressure arranged to provide a pre-compressionforce onto the absorbent core, and more preferably wherein the thirdpressure is less than the first pressure, preferably such that thepre-compression force is less than a force generated by the firstpressure onto said absorbent core. It has been found that applying apre-compression step prior to the final pressure by the first auxiliaryendless surface, allows to achieve a stronger bonding force between topand bottom core wrap layers in the channel region whilst at the sametime allowing to use individually lower pressures that are beneficial toavoiding undesirable damage to the neighboring areas thereof comprisingabsorbent material.

Preferably, the second pressure is greater or equal to the firstpressure. Alternatively the second pressure is less than or equal to thefirst pressure.

In an embodiment, the first, second, third, and/or fourth auxiliarymoving surfaces (12, 13, 14, 15) comprise an outer surface (alsoreferred to herein as “abrading surface”) being made of a substantiallypliable material typically selected from the group consisting ofplastic, rubber, and silicone, preferably pliable material comprisingpolyurethane, more preferably elastic polyurethane.

In a preferred embodiment, the first, second, third, and/or fourthauxiliary moving surfaces (12, 13, 14, 15) comprise a substantiallysmooth outer surface typically free of protruding embossing and/ormating members, said outer surface being made of a substantially pliablematerial typically selected from the group consisting of plastic,rubber, and silicone, preferably pliable material comprisingpolyurethane, more preferably elastic polyurethane. Advantageously, thisimproves the fatigue resistance and allows for higher production speedsto be run without the need for registration.

In an embodiment the first, second, third, and/or fourth auxiliarymoving surfaces (12, 13, 14, 15) are made of a material comprisingpolyurethane and having a Shore A hardness at 85° C. of from 55 to 95,measured according to standard DIN 53505.

In an embodiment the first, second, third, and/or fourth auxiliarymoving surfaces (12, 13, 14, 15) are made of a material comprisingpolyurethane and having a tensile strength of from 9 to 55 MPa, asmeasured according to standard DIN 53504. Advantageously thiscontributes to allowing to omit the use of further springs and/ordampeners.

Preferably, the first, second, third, and/or fourth auxiliary movingsurfaces (12, 13, 14, 15) each comprise, preferably consist of, rotatingpressure rollers.

In a preferred embodiment, the first auxiliary moving surface (12) has awidth, extending perpendicular to the machine direction and parallel tothe axis of rotation thereof, that is greater than the width of each ofthe second and third auxiliary moving surfaces (13, 14), and preferablywherein the fourth auxiliary moving surface (15) has a width, extendingperpendicular to the machine direction and parallel to the axis ofrotation, that is greater or equal to the width of the first auxiliarymoving surface (12).

In an embodiment the width of the first auxiliary moving surface (12),and/or fourth auxiliary moving surface (15), is at least equal to alargest distance D between insert portions taken along an axisperpendicular to the machine direction and parallel to the axis ofrotation (i.e. perpendicular to the longitudinal peripheral edges (19)of the pockets (2)). It is apparent that although FIG. 1 illustrates thelargest distance D when the insert is a single insert in the form of asubstantial U-shape, it will be apparent to a person skilled in the artthat the same will apply to the largest distance D between separate andoppositely disposed inserts forming plural distinct channels.

In an embodiment, the first, second, third, and/or fourth auxiliarymoving surfaces (12, 13, 14, 15) are connected to one or morecompression springs and/or dampeners. This has the advantage ofabsorbing the shocks generated by the rotating inserts as will bedescribed in more detail hereinbelow.

Preferably, the first, second, third, and/or fourth auxiliary movingsurfaces (12, 13, 14, 15) comprise an outer abrading surface (16) and aplurality of fanning out spoke-like members (17) that converge towardsthe rotation axis of said first, second, third, and/or fourth auxiliarymoving surfaces (12, 13, 14, 15), preferably wherein the spoke-likemembers (17) are made of a pliable material comprising, and preferablyselected from, polyurethane, more preferably being the same material asthe abrading surface (16). Advantageously, this arrangement has beenfound beneficial to allow for pressure rollers that themselves absorbshocks created by the impacting/rotating inserts at high speed thusallowing to omit expensive and complex spring, dampeners and swing-armarrangements thus also improving the wear and tear performance ofrespective components through long production cycles at very high speedsof in excess of 900 pieces per minute.

Preferably, the spoke-like members (17) have a minimum and a maximumthickness, wherein the minimum thickness is proximal to an axis ofrotation thereof, and the maximum thickness is proximal to the abradingsurface (16) and distal from said axis of rotation. Preferably, a gap(or void) is formed between each consecutive spoke-like members (17)which when seen in the cross-sectional plane perpendicular to the axisof rotation thereof (as illustrated in FIG. 5) said gap(s) (or void(s))has a substantially triangular shape.

In a preferred embodiment, as illustrated in FIG. 5, the spoke-likemembers (17) form an angle (α) with respect to each other neighboringspoke-like members (17), typically wherein said angle (α) is from 10° to60°, preferably from 15° to 55°, more preferably from 20° to 45°, evenmore preferably from 25° to 40°. Advantageously, this arrangement allowsfor efficiently and effectively allow of shock absorption via bucklingeffects enabled by the spokes which especially when made of a materialselected from polyurethane as described above surprisingly allow for avery resilient and strong structure with sufficient flexibility todeform and return to its original shape upon application of largeforces. This has been found to be an additional enabler for eliminatingexpensive and difficult to maintain mechanical or hydraulic or pneumaticcomponents such as springs and dampeners or the like.

The Process

The present disclosure further relates to a process or method for makingan absorbent core and article, as illustrated in FIG. 6, comprising saidcore having one or more channels, the method may comprise the steps of:i. providing a first endless moving surface (1) comprising a pluralityof molds (2), each mold (2) comprising a non-porous insert (3) therein,typically said insert (3) having the inverse shape of said channel(s),wherein the molds (2) are in fluid communication with an under-pressuresource except for said insert (3); ii. feeding a first nonwoven web (4)to said first endless moving surface (1) and over one or more said molds(2); iii. depositing an absorbent material, comprising cellulose fibersand/or superabsorbent polymer particles, over at least a portion of saidnonwoven web (4); iv. optionally removing said absorbent material fromareas of the nonwoven web (4) corresponding to said insert (3); v.applying a second nonwoven web (5) directly or indirectly over theabsorbent material, or folding said first nonwoven web (4), such tosandwich said absorbent material between upper and lower layers (hereinalso referred to as “core wrap layers or surfaces”) of said nonwovenweb(s) (4, 5); vi. joining said upper and lower layers together at leastin the areas of the nonwoven web(s) (4, 5) corresponding to the insert(3) to form an absorbent core having one or more channels substantiallyfree of absorbent material; vii. optionally joining an acquisitiondistribution layer to said absorbent core, typically a skin facingsurface of said upper layer; viii. optionally laminating said absorbentcore and acquisition distribution layer between a liquid pervioustopsheet and a liquid impervious backsheet; wherein step vi. comprisesthe step of selectively applying a first pressure onto the absorbentcore, preferably only, in a central portion thereof and a secondpressure, preferably only, along peripheral longitudinal side edgesthereof running opposite and parallel to each other and being outboardof said central portion, said central portion corresponding at least toa region of the core comprising said channel(s), and wherein said firstand second pressures are successively applied along a machine direction(MD).

In an embodiment, the disclosure relates to a method for making anabsorbent article comprising an absorbent core comprising one or morechannels, the method comprising the steps of: i. providing a firstendless moving surface (1) comprising a plurality of molds (2), eachmold (2) comprising a non-porous insert (3) therein, typically saidinsert (3) having the inverse shape of said channel(s), wherein themolds (2) are in fluid communication with an under-pressure sourceexcept for said insert (3); ii. feeding a first nonwoven web (4) to saidfirst endless moving surface (1) and over one or more said molds (2);iii. depositing an absorbent material, comprising cellulose fibersand/or superabsorbent polymer particles, over at least a portion of saidnonwoven web (4); iv. optionally removing said absorbent material fromareas of the nonwoven web (4) corresponding to said insert (3); v.applying a second nonwoven web (5) directly or indirectly over theabsorbent material, or folding said first nonwoven web (4), such tosandwich said absorbent material between upper and lower layers of saidnonwoven web(s) (4, 5); vi. joining said upper and lower layers togetherat least in the areas of the nonwoven web(s) corresponding to the insert(3) to form an absorbent core having one or more channels substantiallyfree of absorbent material; vii. optionally joining an acquisitiondistribution layer to said absorbent core, typically a skin facingsurface of said upper layer; viii. optionally laminating said absorbentcore and acquisition distribution layer between a liquid pervioustopsheet and a liquid impervious backsheet; wherein step vi. comprisesthe step of selectively applying a first pressure onto the absorbentcore, preferably only, in a central portion thereof and a furtherpressure onto the absorbent core, preferably only, in the centralportion thereof, wherein said further pressure is applied upstream ofsaid first pressure and arranged to provide a pre-compression force ontothe absorbent core in an area of said core corresponding to saidchannels.

Preferably, the first pressure is applied upstream of the secondpressure. It has been found that by applying pressure to the centralportion/region of the absorbent core as early as possible after themarriage point of the top and bottom core wrap layers (or surfaces) abetter adhesion of said surfaces is achieved with limited risk ofcontaminating the channel region with absorbent material that wouldotherwise reduce the bonding strength between such surfaces and/or leadto damage, such as tearing, of one or more of the core wrap layers. Atthe same time applying the pressures sequentially at different positionsalong the machine direction allow for excess air that is entrappedbetween the core wrap layers to be evacuated from the central portion tothe peripheral longitudinal edges (or the opening formed by the fold)and thus aiding to improve core stability compared to simultaneouslyapplying the first and second pressures.

In a preferred embodiment, as illustrated on FIG. 3-4 and FIG. 5, stepvi. comprises the further step of applying a third pressure onto theabsorbent core, preferably only, in the central portion thereof, whereinsaid third pressure is applied upstream of said first pressure,preferably said third pressure arranged to provide a pre-compressionforce onto the absorbent core in an area of said core corresponding tosaid channels.

In an embodiment, the third pressure is less than or equal to the firstpressure, preferably such that the pre-compression force is less than aforce generated by the first pressure onto said absorbent core.

Preferably, the second pressure is greater or equal to the firstpressure. Alternatively, the second pressure is less than or equal tothe first pressure. In an embodiment, the second pressure is less thanor equal to the third pressure.

In an embodiment, the process comprises the step of applying an adhesivepattern onto the acquisition distribution layer or a skin facing surfaceof the upper layer of the core and laminating said acquisitiondistribution layer to said absorbent core wherein said adhesive patternis positioned inboard and/or outboard of the channel(s) such thatsubstantially no adhesive pattern overlaps with said channel(s), andwherein the acquisition distribution layer comprises a spunbond and/orcarded, typically thermo carded, nonwoven layer. Advantageously,acquisition distribution layers being selected from spunbond and/orcarded nonwovens work synergistically with the channel(s) to providefast liquid drainage and reduce rewet. Indeed, acquisition distributionlayers have evolved from spunbond materials to nowadays more highlyperforming air-through bonded nonwovens, nevertheless it has been foundthat when utilizing a channeled core the sponge-like behavior of highlyporous air-through bonded nonwovens provides for disadvantages in rewetthat outweigh the fluid distribution capabilities that are now for themajority attained by the presence of the channel(s). Moreover, ensuringthat no or minimal adhesive is present in the channel region between thecore and acquisition distribution layer ensures to minimize drawbacks toeffective drainage provided by the channel(s) and thus permitting theuse of spunbond and/or carded nonwovens to be used with added overallperformance as well as reduced cost.

Preferably, the acquisition distribution layer comprises syntheticfibers, wherein said synthetic fibers are comprised at a level ofgreater than 80% wt by weight of said acquisition distribution layer,and wherein said acquisition distribution layer has a basis weight offrom 10 to 50 g/m², and preferably wherein the acquisition distributionlayer is or consists of one or more layers, preferably single-layer, ofspunbond or carded, preferably thermo-carded nonwovens.

In a preferred embodiment, the adhesive pattern is in the form of aplurality of stripes or spirals being spaced apart in a transverse axisextending perpendicular to the machine direction.

In an embodiment, step vii comprises the step of applying pressure tothe acquisition distribution layer and the absorbent core in thechannel(s) such that said acquisition distribution layer is pressed intocontact with the upper layer of the nonwoven web(s), preferably whereinsaid acquisition distribution layer is arranged to be in contact withsaid upper layer in dry state such to form one or more ditches and tofreely displace away from said upper layer in wet state.

1. A method for making an absorbent article comprising an absorbent corecomprising one or more channels, the method comprising the steps of: i.providing a first endless moving surface (1) comprising a plurality ofmolds (2), each mold (2) comprising a non-porous insert (3) therein,wherein the molds (2) are in fluid communication with an under-pressuresource except for said insert (3); ii. feeding a first nonwoven web (4)to said first endless moving surface (1) and over one or more said molds(2); iii. depositing an absorbent material, comprising cellulose fibersand/or superabsorbent polymer particles, over at least a portion of saidnonwoven web (4); iv. optionally removing said absorbent material fromareas of the nonwoven web (4) corresponding to said insert (3); v.applying a second nonwoven web (5) directly or indirectly over theabsorbent material, or folding said first nonwoven web (4), such tosandwich said absorbent material between upper and lower layers of saidnonwoven web(s) (4, 5); vi. joining said upper and lower layers togetherat least in the areas of the nonwoven web(s) (4, 5) corresponding to theinsert (3) to form an absorbent core having one or more channelssubstantially free of absorbent material; vii. optionally joining anacquisition distribution layer to said absorbent core, typically a skinfacing surface of said upper layer; viii. optionally laminating saidabsorbent core and acquisition distribution layer between a liquidpervious topsheet and a liquid impervious backsheet; characterized inthat step vi. comprises the step of selectively applying a firstpressure onto the absorbent core, preferably only, in a central portionthereof and a second pressure, preferably only, along peripherallongitudinal side edges thereof running opposite and parallel to eachother and being outboard of said central portion, said central portioncorresponding at least to a region of the core comprising saidchannel(s), and wherein said first and second pressures are successivelyapplied along a machine direction (MD).
 2. A method for making anabsorbent article comprising an absorbent core comprising one or morechannels, the method comprising the steps of: i. providing a firstendless moving surface (1) comprising a plurality of molds (2), eachmold (2) comprising a non-porous insert (3) therein, wherein the molds(2) are in fluid communication with an under-pressure source except forsaid insert (3); ii. feeding a first nonwoven web (4) to said firstendless moving surface (1) and over one or more said molds (2); iii.depositing an absorbent material, comprising cellulose fibers and/orsuperabsorbent polymer particles, over at least a portion of saidnonwoven web (4); iv. optionally removing said absorbent material fromareas of the nonwoven web (4) corresponding to said insert (3); v.applying a second nonwoven web (5) directly or indirectly over theabsorbent material, or folding said first nonwoven web (4), such tosandwich said absorbent material between upper and lower layers of saidnonwoven web(s) (4, 5); vi. joining said upper and lower layers togetherat least in the areas of the nonwoven web(s) corresponding to the insert(3) to form an absorbent core having one or more channels substantiallyfree of absorbent material; vii. optionally joining an acquisitiondistribution layer to said absorbent core, typically a skin facingsurface of said upper layer; viii. optionally laminating said absorbentcore and acquisition distribution layer between a liquid pervioustopsheet and a liquid impervious backsheet; characterized in that stepvi. comprises the step of selectively applying a first pressure onto theabsorbent core, preferably only, in a central portion thereof and afurther pressure onto the absorbent core, preferably only, in thecentral portion thereof, wherein said further pressure is appliedupstream of said first pressure and arranged to provide apre-compression force onto the absorbent core in an area of said corecorresponding to said channels.
 3. A method according to claim 1 whereinthe first pressure is applied upstream of the second pressure.
 4. Amethod according to any of the preceding claims wherein step vi.comprises the further step of applying a third pressure onto theabsorbent core, preferably only, in the central portion thereof, whereinsaid third pressure is applied upstream of said first pressure,preferably said third pressure arranged to provide a pre-compressionforce onto the absorbent core in an area of said core corresponding tosaid channels.
 5. A method according to claim 4 wherein the thirdpressure is less than or equal to the first pressure, preferably suchthat the pre-compression force is less than a force generated by thefirst pressure onto said absorbent core.
 6. A method according to claim1 or 3 to 5 wherein the second pressure is greater or equal to the firstpressure.
 7. An apparatus (6) for making an absorbent article comprisingan absorbent core comprising one or more channels, said apparatuscomprising: a first endless moving surface (1) in the form of a rotatingdrum, said drum comprising a plurality of molds (2) in the form ofpockets successively positioned along a circumference of said drum,wherein each mold (2) comprises a non-porous insert (3) therein, whereinthe molds (2) are in fluid communication with an under-pressure sourceexcept for said insert (3) such to form one or more non-suction zonescorresponding to said non-porous insert (3) and a suction zonesurrounding said non-porous insert (3); a first feeding unit (7) forfeeding a first nonwoven web (4) to said first endless moving surface(1) and over one or more said molds (2); a first adhesive applicationunit (8) for applying an adhesive pattern over a skin-facing surface ofsaid first nonwoven web (4); an absorbent material deposition unit (9)for depositing an absorbent material, typically comprising cellulosefibers and/or superabsorbent polymer particles, over at least a portionof said first nonwoven web (4); a second feeding unit for feeding asecond nonwoven web (5) directly or indirectly over the absorbentmaterial such to sandwich said absorbent material between upper andlower layers of said nonwoven webs (4, 5) to form an absorbent core; ora folding unit for folding said first nonwoven web (4) such to sandwichsaid absorbent material between upper and lower layers of said nonwovenweb (4) to form an absorbent core; optionally a second adhesiveapplication unit (10) for applying an adhesive pattern over agarment-facing surface of said second nonwoven web (5) positionedupstream a joining position of said second nonwoven web (5) to saidfirst nonwoven web (4); optionally a removing unit (11) for removingsaid absorbent material from areas of the nonwoven web (4) correspondingto said insert (3) such that at least one portion of the nonwoven web(4) located above the suction zone is covered with absorbent materialand substantially no absorbent material is present on portionscorresponding to the non-suction zone; a first auxiliary moving surface(12) for applying a first pressure to the upper and lower layers of saidnonwoven web(s) (4, 5); characterized in that the apparatus (6) furthercomprises a second and third auxiliary moving surfaces (13, 14) forapplying a second pressure to the upper and lower layers of saidnonwoven web(s) (4, 5), wherein said first endless moving surface (1),said first auxiliary moving surface (12), said second auxiliary movingsurface (13) and said third auxiliary moving surface (14) each have anaxis of rotation being substantially parallel to each other, and whereinthe first endless moving surface (1) and the auxiliary moving surfaces(12, 13, 14) act upon each other by applying pressure to the upper andlower layers of said nonwoven web(s) (4, 5), and in that said firstauxiliary moving surface (12) is arranged to selectively apply saidfirst pressure onto the absorbent core, preferably only, in a centralportion thereof and said second and third auxiliary moving surfaces (13,14) are arranged to selectively apply said second pressure, preferablyonly, along peripheral longitudinal side edges of said absorbent corerunning opposite and parallel to each other and being outboard of saidcentral portion, said central portion corresponding to a region of thecore comprising said channel(s).
 8. An apparatus (6) according to claim7 wherein the second and third auxiliary moving surfaces (13, 14) arepositioned downstream of the first auxiliary moving surface (12) along amachine direction (MD).
 9. An apparatus (6) according to claims 7 to 8wherein the second and third auxiliary moving surfaces (13,14) arespaced apart at a distance extending parallel to the axis of rotationthereof, preferably wherein the axis of rotation of said second andthird auxiliary surfaces (13, 14) substantially coincide, morepreferably wherein the second and third auxiliary moving surfaces (13,14) are rotatably connected by a common housing.
 10. An apparatus (6)according to claims 7 to 9 further comprising a fourth auxiliary movingsurface (15) arranged to provide a third pressure onto the absorbentcore, preferably only, in the central portion thereof, wherein saidthird pressure is applied upstream of said first pressure, preferablysaid third pressure arranged to provide a pre-compression force onto theabsorbent core, and more preferably wherein the third pressure is lessthan the first pressure, preferably such that the pre-compression forceis less than a force generated by the first pressure onto said absorbentcore.
 11. An apparatus (6) according to claims 7 to 10 wherein thesecond pressure is greater or equal to the first pressure.
 12. Anapparatus (6) according to claims 7 to 11 wherein the first, second,third, and/or fourth auxiliary moving surfaces (12, 13, 14, 15) comprisea substantially smooth outer surface free of protruding embossing and/ormating members, said outer surface being made of a substantially pliablematerial typically selected from the group consisting of plastic,rubber, and silicone, preferably pliable material comprisingpolyurethane, more preferably elastic polyurethane.
 13. An apparatus (6)according to claims 7 to 12 wherein the first, second, third, and/orfourth auxiliary moving surfaces (12, 13, 14, 15) each comprise arotating pressure roller.
 14. An apparatus (6) according to claims 7 to13 wherein the first auxiliary moving surface (12) has a width,extending perpendicular to the machine direction and parallel to theaxis of rotation thereof, that is greater than the width of each of thesecond and third auxiliary moving surfaces (13, 14), and preferablywherein the fourth auxiliary moving surface (15) has a width, extendingperpendicular to the machine direction and parallel to the axis ofrotation, that is greater or equal to the width of the first auxiliarymoving surface (12).
 15. An apparatus (6) according to claims 7 to 14wherein the first, second, third, and/or fourth auxiliary movingsurfaces (12, 13, 14, 15) are connected to one or more compressionsprings and/or dampeners.
 16. An apparatus (6) according to claims 7 to15 wherein the first, second, third, and/or fourth auxiliary movingsurfaces (12, 13, 14, 15) comprise an outer abrading surface (16) and aplurality of fanning out spoke-like members (17) that converge towardsthe rotation axis of said first, second, third, and/or fourth auxiliarymoving surfaces (12, 13, 14, 15), preferably wherein the spoke-likemembers (17) are made of a pliable material comprising, and preferablyselected from, polyurethane.
 17. The use of an apparatus according toclaims 7 to 16 in making an absorbent article comprising an absorbentcore comprising one or more channels, wherein top and bottom layers ofthe nonwoven web(s) are joined together in an area corresponding to thechannel(s) and, preferably sequentially thereafter, in areascorresponding to the peripheral longitudinal side edges of saidabsorbent core running opposite and parallel to each other and beingoutboard of the central portion of the absorbent core comprising thechannel(s), for increasing production speed and/or avoiding processregistration.